Graco 311365J User Manual

Repair

Ultra

- For Portable Airless Spraying of Architectural Coatings and Paints. For professional use only. Not for use in explosive atmospheres.-

3300 psi (22.8 MPa, 227 bar) Maximum Working Pressure

IMPORTANT SAFETY INSTRUCTIONS Read all warnings and instructions in this

manual. Save these instructions.

See page 3 for model information, including maximum working pressure and approvals. Korean patent 10-0579681

Max II/Ultimate Mx II

ti13459a

311365J

ti13450a

ti13461a

695/795 LOW

695/795 HI

ti13460a

1095/1595 HI

MARK V

Table of Contents ............................2

Models ....................................3

Warnings .................................. 5

Component Identification and Function ........... 8

General Repair Information .................... 9

Pressure Relief Procedure .................9

Grounding ................................10

Troubleshooting ............................11

Mechanical/Fluid Flow ....................11

Electrical ..............................13

Pressure Control Board ......................20

100 - 120 Vac North American and

Japan/Taiwan Motor Control Board ..........20

240 Vac Motor Control Board ..............23

240 Vac Filter Board .....................25

110 Vac U.K. Motor Control Board .......... 26

110 Vac U.K. Filter Board ................. 28

Pressure Adjust Potentiometer .............30

Pressure Control Transducer ...............31

Notes .................................... 33

Drive and Bearing Housing Replacement ........34

Disassembly ...........................34

Assembly .............................. 34

Motor Replacement .........................36

Removal .............................. 36

Installation ............................. 36

Displacement Pump Replacement for 695/795 ....38

Removal .............................. 38

Installation ............................. 39

Displacement Pump Replacement

1095/1595/Mark V ..........................40

Removal .............................. 40

Installation ............................. 41

Wiring Diagram ............................43

Wiring Diagram ............................44

Wiring Diagram ............................45

Wiring Diagram ............................46

Notes .................................... 47

Graco Standard Warranty ....................48

Table of Contents

2 311365J

Models

Vac Model Type Lo-Boy Hi-Boy

120

North America

120

North America

Ultimate Mx II

240

Europe

240

Europe Multi-cord

110

240

Asia

695 Standard 255130 249642

Premium 255131 249644

795 Standard 255132 249646

Premium 255133 249648

1095 Standard 249651

Premium 249653

1595 Standard 253060

Premium 253059

Mark V 249904

1595 Standard 249658**

Premium 249659**

Mark V 249903**

695 Standard 826093 826067

Premium 826094 826069

795 Standard 826071

Premium 826072

1095 Standard 826073

Premium 826074

1595 Standard 826082

Premium 826081

1595 Standard 826075

Premium 826076

695 255134 249663

249666

795

256165

1095 249667

249905

Mark V

256166 695 255135 249668 795 249671

1095 249672

Mark V* 249907

695 249673 795 249674

1095 249675

Mark V 249906

695 255138 249681 795 249683

1095 249684

Models

*Also for Asia and Australia; **Not ETL Approved All models not available in all countries.

311365J 3

Vac Model Type Lo-Boy Hi-Boy

Models

240

Australia

100

Japan & Taiwan

695 255139 249685 795 255140 249687

1095 249688

695 255136 249676 795 255137 249678

1095 249680

4 311365J

Warnings

The following warnings are for the setup, use, grounding, maintenance and repair of this equipment. The exclamation

point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risks. Refer back to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where applicable.

WARNING

GROUNDING

This product must be grounded. In the event of an electrical short circuit, grounding reduces the risk of electric shock by providing an escape wire for the electric current. This product is equipped with a cord having a grounding wire with an appropriate grounding plug. The plug must be plugged into an outlet that is properly installed and grounded in accordance with all local codes and ordinances.

• Improper installation of the grounding plug is able to result in a risk of electric shock.

• When repair or replacement of the cord or plug is required, do not connect the grounding wire to either flat blade terminal.

• The wire with insulation having an outer surface that is green with or without yellow stripes is the grounding wire.

• Check with a qualified electrician or serviceman when the grounding instructions are not completely understood, or when in doubt as to whether the product is properly grounded.

• Do not modify the plug provided; if it does not fit the outlet, have the proper outlet installed by a qualified electrician.

• This product is for use on a nominal 120V circuit and has a grounding plug similar to the plug illustrated in the figure below.

ti9164a

• Only connect the product to an outlet having the same configuration as the plug.

• Do not use an adapter with this product.

Extension Cords:

• Use only a 3-wire extension cord that has a 3-blade grounding plug and a 3-slot receptacle that accepts the plug on the product.

• Make sure your extension cord is not damaged. If an extension cord is necessary, use 12 AWG (2.5 mm2) minimum to carry the current that the product draws.

• An undersized cord results in a drop in line voltage and loss of power and overheating.

311365J 5

Warnings

WARNING

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion:

• Do not spray flammable or combustible materials near an open flame or sources of ignition such as cigarettes, motors, and electrical equipment.

• Paint or solvent flowing through the equipment is able to result in static electricity. Static electricity creates a risk of fire or explosion in the presence of paint or solvent fumes. All parts of the spray system, including the pump, hose assembly, spray gun, and objects in and around the spray area shall be properly grounded to protect against static discharge and sparks. Use Graco conductive or grounded high-pressure airless paint sprayer hoses.

• Verify that all containers and collection systems are grounded to prevent static discharge.

• Connect to a grounded outlet and use grounded extensions cords. Do not use a 3-to-2 adapter.

• Do not use a paint or a solvent containing halogenated hydrocarbons.

• Keep spray area well-ventilated. Keep a good supply of fresh air moving through the area. Keep pump assembly in a well ventilated area. Do not spray pump assembly.

• Do not smoke in the spray area.

• Do not operate light switches, engines, or similar spark producing products in the spray area.

• Keep area clean and free of paint or solvent containers, rags, and other flammable materials.

• Know the contents of the paints and solvents being sprayed. Read all Material Safety Data Sheets (MSDS) and container labels provided with the paints and solvents. Follow the paint and solvents manufacturer’s safety instructions.

• Fire extinguisher equipment shall be present and working.

• Sprayer generates sparks. When flammable liquid is used in or near the sprayer or for flushing or cleaning, keep sprayer at least 20 feet (6 m) away from explosive vapors.

SKIN INJECTION HAZARD

• Do not aim the gun at, or spray any person or animal.

• Keep hands and other body parts away from the discharge. For example, do not try to stop leaks with any part of the body.

• Always use the nozzle tip guard. Do not spray without nozzle tip guard in place.

• Use Graco nozzle tips.

• Use caution when cleaning and changing nozzle tips. in the case where the nozzle tip clogs while spraying, follow the Pressure Relief Procedure for turning off the unit and relieving the pressure before removing the nozzle tip to clean.

• Do not leave the unit energized or under pressure while unattended. When the unit is not in use, turn off the unit and follow the Pressure Relief Procedure for turning off the unit.

• High-pressure spray is able to inject toxins into the body and cause serious bodily injury. In the event that injection occurs, get immediate surgical treatment.

• Check hoses and parts for signs of damage. Replace any damaged hoses or parts.

• This system is capable of producing 3300 psi. Use Graco replacement parts or accessories that are rated a minimum of 3300 psi.

• Always engage the trigger lock when not spraying. Verify the trigger lock is functioning properly.

• Verify that all connections are secure before operating the unit.

• Know how to stop the unit and bleed pressure quickly. Be thoroughly familiar with the controls.

6 311365J

Warnings

WARNING

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Always wear appropriate gloves, eye protection, and a respirator or mask when painting.

• Do not operate or spray near children. Keep children away from equipment at all times.

• Do not overreach or stand on an unstable support. Keep effective footing and balance at all times.

• Stay alert and watch what you are doing.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.

• Do not kink or over-bend the hose.

• Do not expose the hose to temperatures or to pressures in excess of those specified by Graco.

• Do not use the hose as a strength member to pull or lift the equipment.

ELECTRIC SHOCK HAZARD

Improper grounding, setup, or usage of the system can cause electric shock.

• Turn off and disconnect power cord before servicing equipment.

• Use only grounded electrical outlets.

• Use only 3-wire extension cords.

• Ensure ground prongs are intact on sprayer and extension cords.

• Do not expose to rain. Store indoors.

PRESSURIZED ALUMINUM PARTS HAZARD

Do not use 1, 1, 1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents in pressurized aluminum equipment. Such use can cause serious chemical reaction and equipment rupture, and result in death, serious injury, and property damage.

MOVING PARTS HAZARD

Moving parts can pinch or amputate fingers and other body parts.

• Keep clear of moving parts.

• Do not operate equipment with protective guards or covers removed.

• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure in this manual. Disconnect power or air supply.

PERSONAL PROTECTIVE EQUIPMENT

You must wear appropriate protective equipment when operating, servicing, or when in the operating

area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic fumes, burns, and hearing loss. This equipment includes but is not limited to:

• Protective eye wear

• Clothing and respirator as recommended by the fluid and solvent manufacturer

• Gloves

• Hearing protection

CALIFORNIA PROPOSITION 65

This product contains a chemical known to the State of California to cause cancer, birth defects or other reproductive harm. Wash hands after handling.

311365J 7

Component Identification and Function

13.14.

12.

11.

10.

5. 6. 7. 8.

ti13451a

English 1 Premium Digital Display 2 ON/OFF switch 3 Pressure control 4 Prime / Spray valve 5 Filter 6

AutoClean

™

7 Siphon tube 8 Pump 9

Bearing Housing / ProConnect

™

10 Fluid Outlet 11 Drain tube 12 Trigger Lock 13 Model/serial tag 14

WatchDog

8 311365J

™

Switch (not Mark V)

General Repair Information

Pressure Relief Procedure

General Repair Information

NOTICE

To reduce risk of pressure control malfunction:

System pressure must be manually relieved to prevent system from starting or spraying accidentally. Fluid under high pressure can be injected through skin and cause serious injury. To reduce risk of injury from injection, splashing fluid, or moving parts, follow Pressure Relief Procedure whenever you:

• are instructed to relieve pressure

• stop spraying

• check or service any system equipment

• install or clean spray tip

1. Turn pressure control knob to zero.

2. Turn ON/OFF switch to OFF.

3. Unplug power supply cord.

4. Hold metal part of gun firmly to grounded metal pail. Trigger gun to relieve pressure.

5. Lock gun safety latch.

6. Open prime valve. Leave pr ime valve open until ready to spray again.

NOTE: If suspected that spray tip or hose is completely clogged, or that pressure has not been fully relieved after following steps above, VERY SLOWLY loosen tip guard retaining nut or hose end coupling to relieve pressure gradually, then loosen completely. Then clear tip or hose obstruction.

• Use needle-nose pliers to disconnect wire. Never pull on wire, pull on connector.

• Mate wire connectors properly. Center flat blade of insulated male connector in female connector.

• Route wires carefully to avoid interference with other connections of pressure control. Do not pinch wires between cover and control box.

1. Keep all screws, nuts, washers, gaskets, and electrical fittings removed during repair procedures. These parts are not normally provided with replacement assemblies.

To reduce risk of serious injury, including electric shock, do not touch moving or electrical parts with fingers or tools while testing repair. Shut off and unplug sprayer when inspection is complete. Install all covers, guards, gaskets, screws, washers and shroud before operating sprayer.

2. Test repair after problem is corrected.

3. If sprayer does not operate properly, review repair procedure to verify procedure was done correctly. If necessary, see Troubleshooting, page 11, for other possible solutions.

311365J 9

Grounding

Improper installation or alteration of grounding plug results in risk of electric shock, fire or explosion that could cause serious injury or death.

1. Ultra Max II 695, 795 and 1095 100-200 Vac models require a 50/60 Hz, 15A circuit with a grounding receptacle. Ultra Max II 1595/Mark V 120 Vac models require a 50/60 Hz 20A circuit with a grounding receptacle; 220-240 Vac models require a 50/60 Hz, 10A circuit with a grounding receptacle.

Grounding

2. Do not alter ground prong or use adapter.

ti2810a

3. 120 Vac: A 12 AWG, 3 wires with grounding prong, 300 ft (90 m) extension cord may be used. 220-240 Vac: You may use a 3-wire, 1.0 mm (12 AWG) (minimum) extension cord up to 90 m long. Long lengths reduce sprayer performance.

10 311365J

Troubleshooting

Mechanical/Fluid Flow

Relieve pressure; page 9.

Troubleshooting

WHAT TO CHECK

TYPE OF PROBLEM

E=XX is displayed 1. Fault condition exists 1. Determine fault correction from table,

False tripping of WatchDog system. EMPTY is displayed. Pump does not run.

Pump output is low 1. Spray tip worn 1. Follow Pressure Relief procedure Warn-

If check is OK, go to next check

1. Operating conditions out of WatchDog parameters. Pump output is low, see below.

2. Spray tip clogged 2. Relieve pressure. Check and clean spray

3. Paint supply 3. Refill and reprime pump.

4. Intake strainer clogged 4. Remove and clean, then reinstall

5. Intake valve ball and piston ball are not seating properly

6. Suction hose connections 6. Tighten any loose connections. Check for

7. Fluid filter, tip filter, or tip is clogged or dirty.

8. Prime valve leaking 8. Relieve pressure. Repair prime valve.

9. Verify pump does not continue to stroke when gun trigger is released. (Prime valve not leaking.)

10. Leaking around throat packing nut which may indicate worn or damaged packings.

11. Pump rod damage 11. Repair pump. See pump manual 310643

12. Low stall pressure 12. Turn pressure knob fully clockwise. Make

13. Piston packings are worn or damaged

When check is not OK, refer to this column

page 13.

1. Turn pressure down. Refer to operation manual for adjusting. Operate without WatchDog active; see operation manual.

ing, then replace tip. See your separate gun or tip manual.

tip.

5. Remove intake valve and clean. Check balls and seats for nicks; replace if necessary; see pump manual 310643 or

310894. Strain paint before using to remove particles that could clog pump.

missing or damaged seals.

7. Clean filter; see operation manual.

9. Service pump; see pump manual 310643 or 310894.

10. Replace packings; see pump manual. Also check piston valve seat for hardened paint or nicks and replace if necessary. Tighten packing nut/wet-cup.

or 310894.

sure pressure control knob is properly installed to allow full clockwise position. If problem persists, replace pressure transducer.

13. Replace packings; see pump manual 310643 or 310894.

WHAT TO DO

311365J 11

Troubleshooting

WHAT TO CHECK

TYPE OF PROBLEM

If check is OK, go to next check

Pump output is low 14. O-ring in pump is worn or dam-

aged

15. Intake valve ball is packed with material

When check is not OK, refer to this column

14. Replace o-ring; see pump manual 310643 or 310894.

15. Clean intake valve; see pump manual 310643 or 310894.

WHAT TO DO

16. Pressure setting is too low 16. Increase pressure; see pump manual 310643 or 310894.

17. Large pressure drop in hose with

heavy materials

17. Use larger diameter hose and/or reduce overall length of hose. Use of more than 100 ft of 1/4 in. hose significantly reduces performance of sprayer. Use 3/8 in. hose for optimum performance (50 ft minimum).

Motor runs but pump does not stroke

1. Displacement pump pin (32) damaged or missing; see pump manual 310643 or 310894.

1. Replace pump pin if missing. Be sure retainer spring (31) is fully in groove all around connecting rod; see pump manual 310643 or 310894.

2. Connecting rod assembly (43) damaged; see pump manual

2. Replace connecting rod assembly; see pump manual 310643 or 310894.

310643 or 310894.

3. Gears or drive housing damaged, page 34.

3. Inspect drive housing assembly and gears for damage and replace if necessary; see pump manual 310643 or 310894.

Excessive paint leakage into throat packing nut

1. Throat packing nut is loose 1. Remove throat packing nut spacer. Tighten throat packing nut just enough to stop leakage.

2. Throat packings are worn or

damaged

3. Displacement rod is worn or

damaged

2. Replace packings; see pump manual 310643 or 310894.

3. Replace rod; see pump manual 310643 or

310894.

Fluid is spitting from gun 1. Air in pump or hose 1. Check and tighten all fluid connections.

Reduce engine speed and cycle pump as slowly as possible during priming.

2. Tip is partially clogged 2. Clear tip; see tip guard manual 309640.

3. Fluid supply is low or empty 3. Refill fluid supply. Prime pump; see pump manual 310643 or 310894. Check fluid supply often to prevent running pump dry.

Pump is difficult to prime 1. Air in pump or hose 1. Check and tighten all fluid connections.

Reduce engine speed and cycle pump as slowly as possible during priming.

2. Intake valve is leaking 2. Clean intake valve. Be sure ball seat is not nicked or worn and that ball seats well. Reassemble valve.

3. Pump packings are worn 3. Replace pump packings; see pump manual 310643 or 310894.

4. Paint is too thick 4. Thin the paint according to the supplier’s recommendations.

No display, sprayer operates 1. Display is damaged or has bad

1. Check connections. Replace display.

connection

12 311365J

Electrical

Symptom: Sprayer does not run or stops running.

Troubleshooting

Relieve pressure; page 9.

WARNING

To avoid electrical shock or moving parts hazards when

• Plug sprayer into correct voltage, grounded outlet

• Set power switch OFF for 30 seconds and then ON again. This ensures sprayer is in normal run mode.

• Turn pressure control knob clockwise 1/2 turn

• View digital display

covers are removed for troubleshooting, wait 30 seconds after unplugging power cord for stored electricity to dissipate. Keep clear of electrical and moving parts during troubleshooting procedures.

If no digital display is available, use control board status light to troubleshoot problems: Turn ON/OFF switch OFF, remove control cover and then turn power back ON. Observe status light. Blinking LED total count equals digital error code i.e., two blinks equals E=02.

TYPE OF PROBLEM WHAT TO CHECK HOW TO CHECK

Sprayer does not run at all See flow chart, page 19. Digital display is blank Control board status light never

lights Sprayer does not run at all Check transducer or transducer Digital display shows E=02

Control board status light blinks 2 times repeatedly

connections

1. Make sure there is no pressure in the system (see Pressure Relief, page 9). Check fluid path for clogs, such as clogged filter.

2. Use airless paint spray hose with no metal braid 1/4 in. x 50 ft minimum. Smaller hose or metal braid hose may result in high-pressure spikes.

3. Set sprayer to OFF and disconnect power to sprayer.

4. Check transducer and connections to control board.

5. Disconnect transducer from control board socket. Check that transducer and control board contacts are clean and secure.

6. Reconnect transducer to control board socket. Connect power, set sprayer ON and control knob 1/2 turn clockwise. If sprayer does not run properly, set sprayer to OFF and go to next step.

7. Install new transducer. Connect power, set sprayer ON and control knob 1/2 turn clockwise. Replace control board if sprayer does not run properly.

311365J 13

TYPE OF PROBLEM WHAT TO CHECK HOW TO CHECK

Sprayer does not run at all Check transducer or transducer Digital display shows E=03

Control board status light blinks 3 times repeatedly

connections (control board is not detecting a pressure signal).

1. Set sprayer to OFF and disconnect power to sprayer.

2. Check transducer and connections to control board.

3. Disconnect transducer from control board socket. Check to see if transducer and control board contacts are clean and secure.

4. Reconnect transducer to control board socket. Connect power, set sprayer ON and control knob to 1/2 turn clockwise. If sprayer does not run, set sprayer to OFF and go to next step.

5. Connect a confirmed working transducer to control board socket.

6. Set sprayer ON and control knob to 1/2 turn clockwise. If sprayer runs, install new transducer. Replace control board if sprayer does not run.

7. Check transducer resistance with ohmmeter (less than 9k ohm between red and black wires and 3-6k ohm between green and yellow wires).

Troubleshooting

14 311365J

TYPE OF PROBLEM WHAT TO CHECK HOW TO CHECK

Sprayer does not run at all Control is commanding motor to run Digital display shows E=05

Control board status light blinks 5 times repeatedly

but motor shaft does not rotate. Possibly locked rotor condition, an open connection exists between motor and control, there is a problem with motor or control board, or motor amp draw is excessive.

1. Remove pump and try to run sprayer. If motor runs, check for locked or frozen pump or drive train. If sprayer does not run, continue to step 2.

2. Set sprayer to OFF and disconnect power to sprayer.

3. Disconnect motor connector(s) from control board socket(s). Check that motor connector and control board contacts are clean and secure. If contacts are clean and secure, continue to step 4.

4. Set sprayer to OFF and spin motor fan 1/2 turn. Restart sprayer. If sprayer runs, replace control board. If sprayer does not run, continue to step 5.

5. Perform Spin Test: Test at large 4-pin motor field connector. Disconnect fluid pump from sprayer. Test motor by placing a jumper across pins 1 & 2. Rotate motor fan at about 2 revolutions per second. A cogging resistance to motion should be felt at the fan. The motor should be replaced if no resistance is felt. Repeat for pin combinations1&3and2&3.Pin4 (the green wire) is not used in this test. If all spin test is positive, continue to step 6.

Troubleshooting

STEP 1:

STEP 2:

STEP 3:

Green Blue Red Black

311365J 15

+ 33 hidden pages